Sash-weight-molding apparatus



' w. K. LEVERING ET AL SASH WEIGHT vMLDNG APPARATUS June 8 Filed August18.1.' 1924 v s sheets-sheet 1` CHQ Jun.; s., 1926-. y 1,588,242

w.K. LEVERING ET Ax."`

y SASH WE'IIGHT MOLDNG APPARATUS Filed August 18., 1924 3 sheets-sheet2'- June 8 1926. I v I 1,588,242

w. K. LEVERING ET AL SASH WEIGHT MOLDING APARTUS u- Filed Augysp 1924 ssheets-sheet s Patented June 8, 1926.

' UNITED STATES 1,588,242 PATENT OFFICE.

WILSON K. LEVERING AND ERNEST D. LEVERING, OF BALTIMORE COUNTY,

MARYLAND.

, vSASHI-WIEICil-IHCT-IVIOLDING- APPARATUS.

Application filed August 18, 1924. Serial No. 732,747.

The manufacture of sash weights by means of sand molds, the eyes andmembers being formed by means of a green sand core or a metal core orchill, has been carried on extensively and with varying degrees ofsuccess and speed' of operation for many years. The nature of thearticle and the use to which it, is put, permits of the use of a ratherlow grade of casting, but the necessity for forming sand molds andforming and placing the cores, has made itk impossible, on account ofthe necessity for employing skilled help in the production .of molds, toreduce the expense and increase the speed of production to correspond tothe expense and speed of production of plain uncored castings producedby means of automatic molding machines and the like.

Attempts have been made to produce sash weights by means of metal molds,but the diculty incident to the construction and operation ofsuch'molds, and particularlyto cooling .them properly between thecasting operations, have up to the present time prevented theintroduction of metal molds for this purpose to any considerable extent,the sand mold with the green sand core or'metal chill block being themost popular and probably the speediest method of production known orused up to the present time.

The object of the present invention is to provide a metal mold sometimesreferred to as a chill, for the production of sash weights, which iseasily` and conveniently cooled, avoiding burning of the mold anddeformation of the weights, and which can othei-y wise be convenientlyand economically operated.

The present device is in the preferred form provided with a lurality ofalternately operating sets of mold cavities, thereby permitting anintermittent operation of each set of moldswith an' opportunity forcooling each set of' molds while the other set is in operation, withoutinterfering with the continuity of operation of the machine.

The present mold is also Water-jacketed to provide for cooling. While itis understood that water-jacketing of metal molds is not a newexpedient, water-jacketing of the molds in the past has. notbeencompletely successful on account of the formationl of steam ckets,particularly near the top of the cket with. consequent failure of thecooljing process and venting of these pockets has been difficult onaccount of the danger incident to the possible escape of water in thevicinity of the molten metal. This difliculty f 4 has been overcome bythe provision of pet cocks by which the steam can be released and by thearrangement of the circulation of cooling water, so that the latter cannot reach the level of the pet cocks.

The apparatus disclosed also includes improved means for operating themold members, avoiding clogging ofthe parts by dirt and scale, and meansfor forcing the mold parts together and locking them .in close contactat separated points spaced along the rear surfaces of the mold membersto hold the contacting surfaces in close contact and prevent theformation of fins on the castings.

In the accompanying drawing we have illustrated a metalmold or chilllembodying 'the various features of my invention in the preferred form,and also showing a slight modification of the inventionl In thedrawings- Figure 1 is a side elevation of the molding machine ofmyinvention.

Figure 2 is an end elevation of the same taken from theright inFigure 1. l Figure 3 is an elevation looking in the direction of thearrow in Figure 1. at theinside of one of the mold sections showing themold cavities therein.

Figure 4 is a section through two of the mold sections taken lon theline 4, 4 of Figure 6 looking in the direction of the arrow.

Figure 5 is a plan of a sash weight made in accordance with theinvention.

gigure 6 is a top plan of the machine; an 1 Figure 7 is an elevationcorresponding to Figure 3 showing a different arrangement of the moldspaces, particularly adapted to the manufacture of small size weights.

Referring to the drawings by numerals, each of which is used to indicatethe same or similar parts in the different igures,'the machine as showncomprises a plurality, preferably three, of co-operating mold-members 1,

-2 and 3 mounted on a frame 5, consisting of upright parallel side framemembers 6, and means for guiding and reciprocating the mold members 2and 3 alternately toward and into contact with and from the central moldmember 1. The intermediate mold member 1 is stationary and provided onits opposite faces which are contacted by s aid moving members 2 and 3with mold cavities 8 and 9, which co-operate alternately with moldcavities 10 and 11 in the opposed surfaces of the moving mold members 2and 3 in the contacting or molding positions of said respective moldmembers, forming enclosed molding spaces in the desired shape of 'fthesash weights to be produced.

Referring more specifically to the detalls of construction and to theoperative parts of saidmachine, the central stationary mold member 1which extends across the machine from side to side, is provided a1; eachend 1n the form shown with horizontal flanges or ears 12 near thevertical centre of the member 1, which rest on and are secured to theframe members 5 and 6, which latter are provided in the form shown with;corresponding ears or brackets 13 1n which are seated cap-screws orbolts 14, which pass through the ears or flanges 12 and hold the moldmember 1 rigidly in position on the framey members, spanning the spacebetween the said members.

In the form of the invention shown, the moving mold members 2, 3 on theopposite sides of the stationary or intermediate mold member 1, arespaced apart and connected together to form a rigid structure by meansof'thrust rods 16, 17, 18 and 19, which as shown are seated in andsecured to said .transversely to the contacting surfaces of the moldmembers alternately to and into lcontact with and from the intermediateor stationary mold member, one said member moving toward the stationarymember as the other moves away from it.

The respective mold members 1, 2 and 3 are in 'the form ofthe inventionshown, provided with ears 21 at each corner for the reciprocation of theguide or thrust rods 16. Though the manner of securing the rods 16, etc.at their ends in the moving mold members is immaterial, it is noted thattheserodsin the' form shown are threaded at each end for a distanceexceeding the thickness of the respective moving mold members and themoving mold members are spaced by means of nuts 22 threaded on to saidrods to the desired position on the inside, i. e., the side toward thestationary mold member, and the. moving mold members are forced upagainst said spacin nuts 22 by means of nuts 23 on the en s of the rods16', etc.,

turned'up against the outer surfaces of the moving mold members on therespective lsides remote from the stationary mold mem- Referring now toFigures 1 and 2, it will be noted that each of the moving moldmembers`2, 3 is provided with horizontal ears 25 at each end of the moldmember, projecting over and resting on the side frames 6. The sideframes are provided with ways 26 upon which the ears 25 rest and slidein the direction of the length of the side frames, and at right anglesto the contacting surfaces of the mold sections, and these ways areprovided with an upwardly projecting rib or key 27'which engages `aco-operating groove or slot 28 in the corresponding ear. The ways 26support the weight of themoving mold members 2 and 3, which are guidedby the rib or lug 27, and further guided and maintained in alignment andin their relation to each other by the rods 16, 17, 18 and 19.

The moving mold members are preferably actuated by means of a rack 30and pinion 31, and are alternately locked in molding position by meansof cams and 36.

To provide for the reciprocation of the mold sections by the rack andpinion referred tothe moving mold member 2 has a pinion shaft 32extending transversely to the frame members 5 and 6 yand to thedirection of reciprocation, the shaft 32 being mounted in suitablebearing blocks 33 secured to the back of the mold member 2 and providedwith suitable apertures or bearings for the shaft 32. The bearing blocks33 act as followers providing bearing surfaces for the locking cams 35and similar bearing blocks 34 on the other moving mold member 3,providing followers or bearing surfaces for the cams 36. The pinion 31is rigidly mounted on the shaft 32 and the rack 30 which co-operateswith the pinion is .secured to the frame with the teeth depend- -ing toprevent the accumulation of dirt.

The rack is horizontal and extends in the direction of the frame membersand in the direction of reciprocation of the parts.

In moving themold members into and out of molding position, ashereinafter described, the shaft 32 carrying the pinion 31 is rotatedfirst in one direction and then in the other direction by means of ahand. crank 37 rigidly secured to the shaft.

It is easily understood that the moving mold members 2 and 3 beingrigidly connected by the rods 16, 17, 18 and 19, move simultaneously inresponse to the operation of the rack and pinion, and that thestationary mold member having two set-s of mold cavities 8 and 9, oneset on each side, which cavities co-operate with the corresponding setsof ycavities 10 and 11 in the moving mold mem-bers 2 and 3, one saidmoving mold lin the stat-ionary mold memberl 1, and that when pouringinto the mold cavities formed between the moving mold member 3 and thestationary mold member 1 has been completed, the molds being released byoperating the cams and 36, rotation of the hand crank 37 operating therack and pinion.

serves to open the mold cavities 9, 11, releasing the castings andproviding for the cooling of this section of the mold andcloses themold' cavities, 8, 10, moving the mold s member 2 into close contactwith the stationary mold member 1.

An important difficulty previously encountered in theattempt to produceiron and other metal castings b means of metal molds, inthe absence o anelaborate locking mechanism which slowsgdown the operation of themachine to a considerable extent, and correspondingly increases theexpense of the product, is due to the inability to h'old the moldsections in suiliciently close contact during pouring to close the jointbetween the mold sections with the result-that a most objectionable finnecessitating an expensive smoothing operation in cleaning the castingsis formed in the Iplane of separation of the mold sections.

. The present machine includes a closing and locking device which incombination with the other details makes it possible to close therespective co-operating mold scctions at each operation of the machineand force them intosuch close contact as to pracltically eliminate thefin, producing perfect casting or castings which are substantially vperfect in this detail in every inst-ance. The locking device referredto is illustrated in Figures 1. 2 and 6. It consists of a series of cams35 on the shaft 39, ,and a series of cams 36 on the other end of themachine. The cams 35 which as-shown are three in number, onel at eachside of the .machine just inside-the -side frame and one in the middle,are mounted on the shaft 39 at the lefthand end of the mach-ine, as seenin Figure 1, which shaft is provided with suitable bearings 40 in eachside frame. y The cams 35 are operated manually by means of a cam arm 41secured to the shaft 39 at one end, and having a considerable length, sothat any desired' tension may be applied 'in operating the cam lock.-The cams, as

'shown` are substantially semi-circular, each having a hub 42 to encloseland engage the shaft, the hubbeingl near one end of -the long diameterof the cam, so that the radius ofthe cam as measured from the centre ofthe shaft to the follower block 33 increases substantially by harmonicprogression as the cam is rotated from right hand position, as seen inFigure 1. Vhen the corresponding mold reaches molding position and themold is locked by forcing the arm 41' downward and to the right inrighthanded rotation, as seen in Figure 1, the three cams on shaft 39,see Figure 2, force the mold section 2 into close contact with the moldsection 1, and the three cams serve to equalize the pressure, bearing ateach side and inthe middle, and with the assistance of the guidingmembers which so control the moving mold sections as to bring the moldstogether in co-operative relation, the mold sections are placed with thecavities in exact registration and forced together, so that the contactbetween the two mold sections is completely closed, preventing theformation of fins on the castings as aforesaid. The manner of unlockingthe mold section 2 and releasing t-he cams 35 by rotating the shaft 39into lefthanded rotation, and: opening the mold by means ofA rack 30 andpinion 31, dropping the castings from the mold cavities 8, 10, andpermitting these portions of the mold to cool, and moving the section 3into molding position as shown in Figure 1, is obvious, as is also themanner of locking this mold in molding position by means of the cams 36on the shaft 43 controlled by lever arm 44, The mold sections might beactuated by alternate operation of the cams, but the rack and pinion ismuch more convenient and s moother.l

. The methody of cooling the molds by means of water jackets is also ofinterestand of great importance in contributing to the success of theapparatus.

Figure 4 which is a cross-section illustrating the movable mold 3 andfixed mold 1 in closed or pouring position, shows the arrangement of thewater-jackets. The mold sections have thin external walls 46 and thininternal walls 47 surrounding the mold cavities. These walls 4enclosechambersor water-jackets 49 which comprise'the main volume of the moldsections. Each mold section is provided at the top, see particularlyFigure 2, with a pet cock 50 for releasing steam to prevent theformation of steam lpockets at the topy of the water jackets, it beingobvious that steam being lighter than water,'in the absence ofobstructions, will be forced to the top of the jacket, where it may bereleased by means of the pet cocks which are closed in the regularoperationofthe molding machine but 'may belopened after each pouring oreach.l

second or third pouring as the occasion seems tol require, or asdetermined by -experiment. -c ,A

The cooling systemA further' comprises an outlet 51 at the top of eachwater jacket near the level of the top of the mold cavity, see Figure 4,and below the extreme top of the water jacket and below the pet cocks,so as to keep the water level below the pet cocks and to provide for therelease of the steam without releasing the water. There is also a bottomconnection or inlet 52 by which water is supplied to the jackets fromany suitable cooling apparatus or source of cold water, not shown, thewater being led from the outlet 51 to the cooler by gravity by way of ahose 53, and from the cooler to the inlet 52 by a hose 54, the hosebeing offlexible material to provide for the motion of the moving moldmembers. The water entering at 54, 52 is given but a slight head bygravity or pump.

The operation and advantages of the cooling system have been outlined.The water circulation is comparatively slow and the outlet 51 preventsaccumulation of water in the top of the jacket. Continuous circulationis maintained and at frequent intervals the pet cocks 50 are opened torelease steam tending to form steam jackets and prevent the circulationof water in contact with the upper portions of the mold which wouldprevent cooling and hence cause burning and destruction of the moldsurfaces. In this apparatus destruction of the mold by burning isabsolutely prevented, the circulation of coolingswater in coolingrelation to the entire molding surface being maintained throughout theoperation.

In Figure 7 we have shown a view corresponding to Figure 3 looking atone of the mold sections from the inside showing the mold cavities.' Inthis form of mold section we have provided an increased number of moldcavities of reduced size providing for the production of acomparativelylarge number of weights of the small sizes, which are nowlargely in demand, at each pouring. At the top of the mold section is adepression 61 into which the iron is first poured, and a -central canalor duct 62 leads from this central depression and from this canal arelateral ducts 63 leading to each of the mold cavities 60, and at theouter ends of the mold cavities remote from the centralduct A62, we haveshown main vents 64 opening at the top of the mold section and parallelto the central duct62, and leading to this vent from each of the moldcavities 60 is a branch vent 65 whereby the gases accumulated in themold cavities and air impounded therein are released, preventing theformation of bubbles inthe 'castmgs u u The o eration of the moldingapparatus and the unctioning of the various improvements has been fullyexplained in connection with the description ofthe apparatus. The movingmold sections 2 and 3 being of the molds by meansof circulation of waterthrough the jackets, and the manner of maintaining the level of thecooling water below the top of the water jacket and below the pet cocksby means of which the steam is released after every molding. operationor every second or third molding operation to prevent the formation ofsteam pockets which would impede the circulation and keep the water outof contact with the upper portions of the mold surface. By thusmaintaining the level of the water below the pet cocks an escape ofwaterin the vicinity of the me ted iron is prevented.

We have thus described specifically and in detail a machine embodyingour invention in the preferred form and a slight modification thereof,the specific description being provided in order that the invention andthe manner of using the same may be clearly understood; however, thespecific terms herein are used descriptively rather than in a limitingsense, the scope of the invention being defined in the claims.

vWhat we claim and desire to secure by` Letters Patent is:

1. In an apparatus for molding sash weights, two mold members, means forsecuring said mold members together and spacing them apart, said moldmembers having mold cavities in their opposed faces, an intermediatemold member between said spaced mold members,- said intermediate moldmember having corresponding mold cavities in its opposite faces adaptedto register and co-operate with the mold cavities in the spaced moldmembers, and means for reciprocating some of said moldl members to bringthe faces of the spaced mold member alternately into contact with thecorresponding faces of the intermediate mold member and cause thecavities in the respective spaced mold members to co-operate alternatelywith the corresponding cavities in the intermediate mold memberproviding for the'alternate closing of one set of mold cavities inmolding position, and the simultaneous opening and cooling of the otherset of mold cavities, releasmg the castings therefrom.

2. In an apparatus for molding sash weights, two mold members, means forsecuring said mold members together and -spacing them apart, said moldmembers hav- 'cavities in its opposite faces adapted to register andco-operate with the mold cavities in the spaced mold members and meansfor moving part of said mold members, causing the cavities of the spacedmold members to co-operate alternately with the cavities in theintermediate mold member.

3. In an apparatus for molding sash weights, two mold members, meanssecuring said mold members together and spacing them apart, said moldmembers having mold cavities in their adjacent opposed faces, a moldmember intermediate of said spaced mold members, the intermediate moldmember having mold cavities in its opposite faces, the cavities in thesaid respective opposite faces being adapted to register and co-operatewith the mold cavities in the respective spaced mold members, and meansfor reciprocating the spaced mold members, bringing their opposed facesalternately into contact with the corresponding faces of theintermediate mold member, causing the cavities in the spaced moldmembers to co-operate alternately with the correspondig cavities in theintermediate mold mem- 4. In an apparatus for molding sash weights, twomold members, means securing said mold members together and spacing themapart, said mold members having mold cavities in their opposed faces, amold member intermediate of said spaced mold members, the intermediatemold member having mold cavities in its opposite faces adapted tore'gister and co-operate with the mold cavities in the spaced moldmembers, and means for reciprocating and guiding the spaced moldmembers, bringing their opposed faces alternately into contact with thecorresponding faces of the intermediate mold member, causing thecavities in the spaced mold members to co-operate alternately with thecorresponding cavities in the third -mold member, and separatelyoperable means for locking each of said spaced mold members alternatelyin close contact with said intermediate mold member, said locking meanscomprising a plurality of locking units spaced apart and engaging saidmold member at widely separated points, causing it to contact the fixedmold member uniformly throughout the engaging surfaces, andV means 'foractuating said respective sets of locking units for each said spacedmold member simultaneously.

5. In' an apparatus YforI molding sash weights, two mold members, meanssecuring said mold members together and spacing them apart, said moldmembershaving y mold cavities in their opposed faces, a mold memberintermediate of said spaced mold members, the intermediate mold memberhaving mold cavities in its opposite faces adapted to register andco-operate with the mold cavities in the spaced mold members,

each of said spaced mold members alter7 nately in close Contact withsaid intermediate vand separately operable means for locking moldmember, "said locking means comprising a plurality of locking unitsspaced apart and engaging said mold member at widely separated points,causing it to contact thev fixed mold member uniformly throughout theengaging surfaces, and means for actuating said respective sets oflocking units for each said spaced mold member simultaneously.

6. In an apparatus for molding sash weights, two mold members, meanssecuring said mold members together and spacing them apart, said mold.-members having mold cavities in their opposed faces, a mold memberintermediate of said spaced mold members, the intermediate mold memberhaving mold cavities in itsopposite faces adapted to register andco-operate with the mold cavities in the spaced mold members, and means`for reciprocating and guiding the spaced mold members, bringing theiropposed faces alternately into contact with the corresponding faces ofthe intermediate mold member, causing the cavities in the spaced moldmembers to co-operate alternately with the corresponding cavities in thelthird mold member, and separately operable means for locking each ofsaid spaced mold members alternately in close contact with saidintermediate mold member.

7,'-In an apparatus for molding sash weights, two mold members,meanssecuring said mold members together and spacing them apart, said moldmembers having mold cavities in their opposed faces, a mold memberintermediate of spaced mold members, the intermediate mold member havingmold cavities in its opposite facesv adapted to register and co-operatewith the mold cavities in the spaced mold member, and separatelyoperable/means for locking each of said spaced mold members alternatelyin close contacty with said inter-v l mediate mold member.

8. In a molding apparatus, a stationary mold member having mold cavitiesin its said pair of mold members simultaneously, bringing first one andvthen the other of said pair of mold members into contact with thestationary mold member in operative molding position while the other ofsaid pair of mold members is spaced' awayfrom the stationary mold memberand permitted to cool, said .means comprising a rack and pinion, therack teeth being vturned downwardly to prevent the accumulation of gritand scale, and means for locking each saidv respective mold members ofsaid pair in cooperative position in relation to said fixed mold membercomprising a cam shaft adjacent each said mold members of said pair, andcams on said shaft s aced apart and engaging widely separate points onsaid mold member.

9. In an apparatus for molding sash weights, two mold members, meanssupporting said mold members in spaced relation, said mold membershaving mold cavities in their opposed faces, a third mold memberintermediate of said spaced mold members having mold cavities in itsopposite faces, the mold cavities on the respective sides of saidintermediate mold member corresponding to and being adapted to registerwith the opposed mold cavities in the adjacent faces of said spaced moldmembers, part of said mold members being movably mounted, and means forguiding part of l said mold members to bring the adjacent surfaces ofthe intermediate mold member alternately in contact with the opposedsurfaces of the spaced mold members, causing the set of correspondingcavities on one side to register, forming sash weight mold spaces andsimultaneously opening cavities on the opposite side, spreading themolds apart, and permitting them to cool, and vice versa.

10. In an apparatus for molding sash weights, two mold members, meansrigidly connecting said moldl members in spaced relation, said moldmembers having mold cavities in their opposed faces, a third mold memberbetween said spaced mold members having mold cavities in its oppositefaces, the mol-d cavities on the respective sides of said mold membercorresponding to and being adapted to register with the op osed moldcavities in the adjacent faces o said i l, spaced mold members, saidrigid connecting means comprising guide members with cooperating guidingmeans on the third mold member, and means for reciprocating said rigidlyconnected mold members to bring the adjacent surfaces of theintermediate mold member alternatel in contact with the opposed surfaceso the spaced mold members, causing the set of corresponding cavities onone side to register, forming sash weight mold spaces and simultaneouslyopening cavities on the opposite` side,

spreading the molds apart, and permitting them to cool.

11. In an apparatus for `molding sash Weights, two mold members, meansconnectsaid mold members having mold cavities in their opposed faces, athird mold member said mold members in spaced relation,l

between said spaced mold members having mold cavities in its oppositefaces, and having guiding means, the mold cavities on the respectivesides of said mold member corresponding to and being adapted to registerwith the opposed mold cavities in the adjacent faces of said spaced noldmembers, means for moving part of said mold members, placing the moldmembers in alternate positions of registration of said cavities, and lmeans for locking said molds in the alternate positions of registration,comprising a plurality of sets of cams spaced apart and engaging widelyseparated points on said mold members, and means for actuatingeach saidset of cams simultaneously.

12. In an apparatusy for .molding sash weights, two mold members, meanssupporting said mold members in spaced relation, said mold membershaving mold cavities in their opposed faces, a third mold member betweensaid spaced mold members having mold cavities in its opposite faces, themold, cavities on the respective sides of said mold member correspondingto and being adapted to register with the op osed mold cavities in theadjacent faces o said spaced mold members forming sash weight moldspaces, and means for cooling said mold members comprising water-jacketssurrounding' said mold cavities, anA outlet near the top of the moldcavities for removin water from said jacket, means for supplying waterat a lower point to said water jackets, and a steam cock at the top ofeach of said water jackets for releasing steam and preventing steampockets therein.

13. In a mold for sash we1ghts, a plurality of mold members, means forguiding and moving one of said mold members toward and\ into contactwith and from another mold member, said mold members having moldingcavities which register in the positions of contact, a water jacketsurrounding said molding cavities, connections thereto, providing forthe circulation of water inadjacent faces and separate clamping 4meansfor locking said mold members in close contact.

15. A two-part metal mold for sash molding members, permitting it to bemoved toward and into contact with and away from the other mold memberand means for moving said mold member comprising a rack and pinion, therack teeth. being turned downwardly, and independent means for lockingsaid members in close contact.

16. A sash Weight molding apparatus comprising a metal moldvv formed ina plurality of parts, means for guiding one of said parts toward andinto contact with and away from the other of said parts, co-

operating mold ,cavities in the contacting surfaces of said mold parts,said mold cavitles belng elongated in a horizontal direction and placedone over the 'other in parallel, Weights, guiding means for one of saidand having adjacent one end of said cavities a vertical passage for theadmission of the molten metal, passages connecting said cavities to saidvertical passage at one end, an upright vent passage opposite the otherend of the mold cavities, and short passages connecting each mold cavityto each said upright vent passage.

In testimony whereof we aiix our signatures.

WILSON K. LEVERING. ERNEST D. LEVERING.

